Friction elements bonded with a reaction product of polymerized linseed oil, sulfur and phenol-aldehyde resin mixed with a butadieneacrylonitrile copolymer



Sept. 30, 1947.

- Pira-A7' lass .5y zwanz- R. E. sPoKEs ET Al. v 2,428,299

FRICTION ELEMENTS BONDED WITH A REACTION PRODUCT OF POLYMERIZED LINSEED OIL, SULFUR AND PHENOL-ALDEHYDE WITH Av BUTADlENE-ACRYLONITRILE COP Original Filed Nov. 16, 1942 ESIN MIXED LYMER 2 Sheets-Sheet 1 zwc.

imm?- (j fuk/Qur?) Sept 30, l947- R. E. sPoKl-:s Er Ax. 2,428,299

FRICTION ELEMENTS BONDED WITH A REACTION PRODUCT 0F POLYMERIZED LINSEED OIL, SULFUR AND PHENoL-ALDEHYDE RESIN MIXED WITH A BUTADIENE-ACRYLONITRILE coPoLYMER Original Filed Nov. 16. 1942 2 Sheets-Sheet 2 zxmsm- WM5 J/v Hawks/frias?? tures frequently -in friction elements fr such friction elements Patented Sept. 30, 1'947 FRICTION ELEMENTS ACTION PRODUCT O SEED OIL, SULFUR HYDE RESIN MIXED BONDED WITH A RE- F POLYMERIZED LIN- AND PHENOL-ALDE- WITH A BUTADIENE- ACRYLONITRILEA COPOLYDIER Ray E. Spokes, Ann Arbor, and Emil C. Keller, Detroit, Mich., assignors to American Brake Shoe Company, Wilmington,

of Delaware Del., a corporation 8 Claims.

tion material, such, for example, as asbestos, toi, gether with an organic binder and other organic or mineral friction-controlling or imparting agents, together with other materials which may be employed for imparting specific properties or characteristics to such friction elements, such, for example, as greater heat resistance, greater coefcient of friction, and the like.

Friction elements which are intended for heavy duty use upon heavy automotive trucks, buses and the like are commonly subjected to' severe service conditions, that is to say, they are subjected in use to repeated and often prolonged braking operations which develop high temperatures in such friction elements, such temperaapproaching 1000 F. on the friction surface of the friction elements, and progressively lower temperatures inwardly of the friction surfaces thereof. Such high temperatures, especially when occurring or, repeated frequently, tend to depolymerize ory'otherwise decompose organic bonding materials, as well as other organic bonding materials .which may beincorporated in friction elements', including finely divided granulated or so-called dispersed discrete particles of vulcanized natural soft scrap rubber, finely divided particles of cashew nut shell liquid polymer, or nely divided particlesof heat polymerized drying oils, whichghave been employed the purpose of imparting desirable characteristics to such friction elements, including greater or more stable coefcient of friction, improved wear, and the like. Accordingly, there is a consequent tendency of y to exhibit/loss of stability of friction characteristics due to heat decomposition or due to carbonization of the organic bonding and other agents therein and due/ to the resulting presenceon the friction surface or within such friction elements of depolymerized and otherwise liquefied products of heat decomposition of such organic bonding and other materials. The loss of stability, as aforesaid, in friction eletion element.

yments containing nely divided dispersed and dust-like particles heretofore employed may result from the heat decomposition of such organic bonding and other agents and the consequent formation of a high percentage of benzolextractable material, and accompanying formation of a glazed surface, or may be enhanced by carbonization of such organic bonding agents and other materials or by both of such causes, lIt may be said, however, that such loss of friction stability results largely from the baking on the friction surface of the products resulting from the heat decomposition of the organic bonding agent or agents and other materials employed in such friction elements.

Moreover, the glazed illm thus formed on the friction surface of friction elements bonded with organic bonding agents, and which friction elements may contain finely divided and dispersedv dust-like particles composed of the materials referred to hereinbefore, cannot readily be removed and is not self-removing since itdecreases subsequent friction and heat formation so that a fric-V tion element with such a surface not only loses stability of friction characteristics but tends to retain the undesirable glazed lm which causes this instability. Hence; it will be seen that a friction element so affected cannot recover desired frictional stability through normal use of the fric- Moreover, this is also true when the organic bonding agents or the nely divided frictiy n-controlling organic particles dispersed in suclriction elements undergo carbonization due to t e heat of friction incidental fto the use of :friction elements embodying such materials.

These conditions are commonly known in the art as fade and recoveryl Moreover, when the glazed condition, which is referred to hereinbefore, occurs, it is necessary to apply much greater braking forces than normally employed, and under such,conditions,

and with a softened bond or friction-controlling 4 agent, greater shearing forces are exerted within i, .2,428,299y UNITED STATES PATENT OFFICE A to control and vary tion with such finely divided amaca sulting in rapid wear.

Hence, it will be seen that it is important and desirable that the bonding and friction-controlling agents employed in friction elements, and especially in heavy duty friction elements which 1 are subjected to the severe service conditions and high temperatures referred to above, be able to withstand such severe usage and high temperatures withoutundergoingl excessive heat decomposition or carbonization of such organic bonding or friction-controlling agents employed therein and' resulting loss of stable friction characteristics under varying operating conditions,

Various attempts have heretofore been made to overcome the foregoing and other diieulties which have been experienced 'in the use of friction elements embodying organic bonding and friction-controlling agents and among such attempts have been the use of the various materials referred to above, namely, vulcanized soft scrap rubber, cashew nut shell liquid polymer, heat polymerized vegetable drying oils, and sulphurized oils, in the form of finely divided granules or so-called dispersed discrete particles, for controlling the friction characteristics of such friction elements or for preventing or inhibiting or compensating for decrease in the coemcient of friction in such friction elements, incidental to increasing temperaturesfand so as to endeavor to maintain a substantially constant coefficient of friction under continuous service conditions.

While such finely divided friction controlling granules or so-called dispersed discrete particles, composed of the materials referred to hereinbefore, have, in certain instances, imparted desirable characteristics to friction elements in which such 4finely divided particles have been incorporated, we have found that such materials, are not always or entirely satisfactory and have had objectionable properties and undesirable characteristics including those hereinafter indicated. Thus, for example, we have found that such finely divided particles undergo either substantial and excessive heat decomposition or disintegration and softening, or excessive carbonization, as a. result of the high temperatures developed in the use of friction elements under severe service conditions and for prolonged periods of time, as will be referred to more specifically hereinafter, with consequent decrease in coefficient of friction and loss of other friction-controlling characteristics in friction elements employing such materials. n

Moreover, the only way in which it is possible the hardness and related properties and characteristics of finely divided particles of vulcanized soft scrap natural rubber, and the properties imparted thereby to friction elements in which such particles may be employed as a friction-controlling or friction-stabilizing ingredient, is by controlling the degree or extent to which such particles of soft scrap rubber are vulcanized. Further, the only way in which it is possible to control the hardness of finely divided particles of cashew nut shell liquid polymer, and the propertiesand characteristics imparted thereby to friction elements in which such particles may be employed as a. friction-controlling or friction-stabilizing ingredient, is by the use of a resin of the phenolic-aldehyde type in conjuncpartlcles of cashew nut shell liquid polymer particles to render said particles harder and more heat-resistant. Howpractice of the present invention the hardness and heat-resistance of the finely divided or dustlike friction-stabilizing particles may be easily and readily controlled and varied by employing in the making of said particles material havinga selected and predetermined composition. Stated otherwise, in the practice of the present invention there is employed in making said finely divided friction-stabilizing particles a copolymer material, which will be referred to hereinafter, and the hardness and heat resistance and related properties of said finely divided or dust-like particles may be varied and controlled by employing in the making thereof a copolymer material which contains a, selected and predetermined percentage of one component thereof inasmuch as the hardness and heat resistance and related properties of said finely divided or dust-like particles vary directly, that is, increase or decrease. in direct relationship to the percentage of said component in said copolymer material.

Other materials have also been employed in friction elements in an endeavor to control and stabilize the coefficient of friction and other friction characteristics thereof and to prevent decrease in coemcient of friction under varying and continuous service conditions, and such materials have included small amounts of harsh abrasive materials. However, such harsh abrasive materials have not been entirely satisfactory inasmuch as such harsh' abrasive materials sometimes exert an undesirable scoring effect upon brake drums and the like with which friction elements are used. Moreover, there is a tendency for such abrasive particles to pulverize upon the surface of friction elements embodying the same with consequent undesirable increase in abrasiveness and greater tendency toward scoring of brake drums and the like with which such friction elements are used.

Accordingly, an pbject of the present invention is to afford a new and improved friction element, and method of making the same, which is substantially free from the foregoing and other disadvantages and objectionable features which have beenexperienced heretofore in the use of friction elements containing organic bonding agents and embodying finely divided dust-like particles or so-called dispersed discrete particles composed essentially of the various materials hereinbefore referred to and which have been employed heretofore as friction-controlling or friction-stabilizing agents.

A further object of the invention is to afford 9, new and improved friction element and method of making the same which imparts substantially uniform friction characteristics to such friction elements under continuous and varying and severe service conditions and preventssubstantial loss of or decrease in the coeflicient of friction therein, due to break-down of the bonding agent or friction-controlling agent employed therein by reason of the heat of friction incidental to the severe usage of vsuch'friction elements, thereby maintaining the coefficient of friction in such friction elements substantially constant, while, at the same time, being substantially free from or highly resistant to carbonization at the high temperatures to which such friction elements are subjected in use.

Another object of the present invention, ancillary to the foregoing objects, is to afford a new and improved friction element which is adapted for heavy duty use upon heavy trucks, buses and ever, as will be pointed out hereinafter, in the 7| the like, as well as for use upon passenger cars and light trucks, particularly when they may lie operated under severe conditions, and which embodies as a friction-controlling agent finely divided dust-like particles which resist heat decomposition and heat depolymerization and excessive y f softening and loss of friction stability resulting from such decomposition, and whi-ch are also highly resistant to carbonization at the high ternperatures to which such friction elements are subjected in use. l'

An additional object of the Ipresent invention is to afford a new and improved friction element, and method of making the same, employing finely divided particles of a synthetic rubber-like elastoprene of the butadiene-acrylonitrile copolymer type as a friction-controlling or friction-stabilizing ingredient therein and in which the desired degree of hardness and heat resistance and reinthe form of finely divided dust-like particles or r, so-called dispersed discrete particles composed of lated properties and characteristics which it may be desired to impart to said finely divided particles, and to a friction element containing said particles, maybe readily controlled amd varied by employing in the making of said finely divided particles abutadiene-acrylonitrile copolymer containing a selected and predetermined percentage of acrylonitrile as a component of the copolymer material.

A further object of the present invention, anl cilla-ry to the immediately preceding object, is to afford a new and improved friction element, and method of making the same, containing as a friction-controlling or friction-stabilizing ingredient finely divided particles of a synthetic rubber-likel elastoprene of the butadiene-acrylonitrile copolymer type and which particles possess improved properties and characteristics as Acompared to finely divided particles of vulcanized soft scrap rubber including markedly superior heat resistance and the additional desirable advantage Which resides in the fact that the degree of such increased or superior heat resistance possessed by the new friction-stabilizing particles may be predetermined and controlled and varied by employing in the making of said new frictionstabilizing particles a butadiene-acrylonitrile copolymer containing a selected and predetermined percentage of acrylonitrile, thus enabling friction elements containing said friction-stabilizing particles to be readily adapted or adjusted to particular and varying requirements and uses.

Other and further objects of the present invention will be apparent from the following description and claims and from the accompanying drawings. In the drawings, ,x

Figs. 1 and 2 are' graphs illustrating certain properties or characteristics of finely divided particles composedl of materials heretofore employed as friction-controlling ingredients in friction elements and illustrating comparable properties or characteristics of the friction-controlling 4 employed heretofore as .the materials heretofore employed for this purpose, while at the same time being free from the aforesaid and other objectionable characteristics tionelements lembodying as a frict'ion-controllin i or friction-stabilizing ingredient finely divi ed dust-like particles composed essentially of one or more vulcaniza'ble syntheticv rubber elastoprenes or so-called synthetic rubbers of the butadieneacrylonitrile copolymer type, compounded with a relatively low sulphur content, are highly resistant to heat/decomposition and heat depolymerization and..-carbonization even at the high temperatures towhich heavy duty friction elements are subjected in use upon heavy duty trucks and buses and the like. Moreover, we have ascertained that friction elements embodying the finely divided dust-like materials which have been found useful and advantageous as friction-controlling agents in the practice of the present invention do not' tend to form a relatively high percentage of benzol-extraotable material upon being subjected to relatively high braking temperatures and hence dolnot tend to exhibit the consequent loss of friction stability which is exhibited |by friction elements embodying the finely divided dust-like materials which have been friction-controlling agents in friction elements, but retain substantially their original friction stability and other desirable characteristics. y

Hence, it will be seen that the-present invention is primarily concerned with friction elements containing as a friction-controlling yingredient finely divided particlesor dust-like materials ,composed essentially of one or more vulcanizable synthetic vulcanized rubbery butadiene-acrylonitrile copolymer elastoprenes, compounded with a low sulphur content, and which mayI be subjected to severe service conditions without exhibiting objectionable heat decomposition or heat depolymerization and softening or carbonizationresulting from or incidental to the high temperatures and severe service conditions I to which friction elements are frequently subjected in use, andas may occur in the use of friction elements embodying as a friction-controlling ingredient therein the finely divided particles or dust-like materials heretofore employed for this purpose while being, at thevsam'e time, substantially free from the objectionable characteristics of the harsh finely divided abrasive materials which have been employed heretofore ,as friction-controlling ingredients in friction elements.

The class of finely-divided particles or dust-like materials which may be employed as frictioncontrolling or friction-stabilizing agents in friction elements, in the practice of thefpresent invention, is` that class` of vulcanizable synthetic rubbery elastoprenes or so-.called synthetic rubbers which are essentially copolymers of the butadiene-acrylonitrile type and which are exemplified by, but not limited to, the disclosure of United States Letters Patent No. 1,973,000, granted September 11, 1934.

We have found that such materials have desirable properties asfriction-controlling agents in friction elements in the practice of the present invention including resistance to heat decomposition and heat depolymerization and softening, as weil as resistance to carbonization, under the high temperatures experienced in the severe usage of such friction elements, while still possessing a substantial degreeor amountof resili- Vency and even after prolonged and severe usage and exposure to the high temperatures incidental thereto. Moreover, resiliency in such finely divided and dispersedparticles is of particular significance in that it enables the finely divided particles which are employed as friction-controlling agents in friction elements to compensate for such loss of friction -stability and decrease in coeiiicient of friction which might otherwise occur if it were not for the resiliency which is inherent in the finely divided or dust particles composed essentially of one or more synthetic vulcanizable ruhbery elastoprenes og the butadiene-acrylonitrile copolymer type which are employed as friction controlling agents in friction elements inthe practice of the present invention. A

While a certain degree or amount of resiliency is inherent in the nely divided particles of soft scrap rubber, and in the finely divided particles of heat polymerized drying oils and, to a somewhat greater degree in the particles of cashew nut shell liquid polymer, which have been em-4 ployed heretofore in friction `elements as frictioncontrolling agents, such resiliency as is possessed by these materials is present therein only in the earlier stages of the use of such materials in friction elements and the resiliency of such materials is substantially lost or decreased either by heat decomposition or carbonizatlon of such materials incidental tothe use thereof as friction-,controlling agentsin friction elements, as referred to hereinbefore.

Other types of synthetic elastoprenes or socalled synthetic rubbers are, of course, known, and among these are those of the butadiene-styrene copolymer vtype which are exemplified by the disclosure of United States Letters Patent No. 1,938,731, granted December 12, 1933, and the non-vulcanizable chloro-butadiene or -chloroprene type of polymers, which have been referred to above, and which are known as Neoprene," Dupr`ene, and the like.

- We have found, however, that finely divided or dust-like particles composed essentially of synthetic elastoprenes of the butadiene-styrene copolymer type, as well as those of the chloro-butadiene type, do not possess or impart to friction elements the desirable characteristics, including friction stability, and resistance to heat decomposition and carbonization, which are imparted to friction elements by finely divided particles composed essentially of synthetic elastoprenes of the butadiene-acrylonitrile copolymer type compounded with a relatively low sulphurV content, as in the practice of the present invention. The present invention is, therefore, `primarily concerned with friction elements embodying as friction-controlling or friction-stabilizing agents therein nely divided dust-like materials or socalled dispersed discrete particles composed essentially of vulcanizable synthetic rubber-like elastoprenes or s o-called synthetic rubbers of the butadiene-acrylonitrile copolymer type, compounded with preferably from about ve percent to about ten percent, by weight, of sulphur, and to which more specific reference will now be made.

The relationship of the monomer components and the general type of synthesis of the copolymer nuclei of the group of class of vulcanizable syn- Vthetic elastoprenes or so-called synthetic rubbers which are referred to above and which I have found to be useful as friction-controlling or friction-stabilizing agents in friction elements, in the practice of the present invention, may be illustrated as follows (J. I. E. C., vol. 34, No. 2, pp. 24S-251, and News edition, Am. Chem. Soc., 19, 750 (1941), and revision, Chem. and Eng. News, vol. 20, No. 8, April 25,k 1942, pp. 536, 537, 538):

n H H n H H H H E H H H o=cc=c c=c -C-o--C-c=c-C- H n H N H H H il Perbunan" Bunt N" Hycar 0R" or Hycar N incne B" (Goodrich) Chemigum ("X* or I) (Goodyear) l Stanco (Standard Oil of New Jersey) It will be understood in connection with the general type of synthesis or copolymerization i1- lustrated above that certain of the materials which are employed in or are necessary in such syntheses,V including the emulsifying, wetting, modifying and catalytic agents which are employed-in the synthesis of the above mentioned butadiene-acrylonitrile copolymer type synthetic rubber-like elastoprenes, are trade secrets, although all of these materials are known to be essentially copolymers of the butadiene-acrylonitrile type.

All of the synthetic elastoprenes or so-called synthetic rubbers referred to above, and which are known to be useful as friction-controlling or friction-stabilizing materials, in the practice of the present invention, are currently available upon the market incommercial quantities, under the trade names referred to.

It will be seen', therefore, from the foregoing description, and from the disclosures referred to therein, that the present invention is primarily concerned with friction elements containing organic bonding agents and which friction elements contain as an ingredient thereof a friction-controlling agent in the form of dust-like materials orso-called finely divided dispersed discrete particles composed essentially of one or more vulcanizable synthetic rubber-like elastoprenes or so-called synthetic rubbers of the character obtained by copolymerization (under conditions and in the presence of other materials, such, for example, as those which are disclosed in Patent No. 1,973,000) of an unsaturated diolenic or butadiene hydrocarbon of the type Y Product:

where a: represents either hydrogen or an alkyl group, and a compound (an acrylonitrile) of the type where R represents either hydrogen, as in acrylic lacid nitrile, per se, or an alkyl group, as in methacrylic acid nitrile, to form a synthetic rubber-like high molecular Weight elastoprene of the butadiene-acrylonitrile copolymer type, followed by compounding the product thus obtained with a relatively low percentage of sulphur and which is preferably not substantially less than ve percent nor substantially more than ten percent, by weight, of the copolymer, and then finely herein contemplated.

dividing the sulphurized product thus obtained into relatively small particles or granules which may :be dispersed with substantial uniformity throughout friction elements" of the character A suitable formula which may be followed in ,making friction elements for normal heavy duty service, in the practice of the present invention, is the following, in which all parts indicated are i by weight: 10

Example No. 1

Parts by weight Heat polymerized vegetable drying oil (linseed) 8.4 15 Oil modified phenol-formaldehyde resin 8.4 Lead formate .a 9.0 Potassium dichromate 1.0 Vulcanized butadienefacrylonitrile copolymer @synthetic rubber-like elastoprene (flnelygdivided dust-like particles, vulcany, ized with ten percent sulphur, by weight) 4.0

Pyrobituminous material (soft coal, finely divided) 1 15.0 Asbestos fiber 65.0 Sulphur 2.5

A suitable formula which may be followed, in the practice of the present invention, in making friction elements which may be subjected to exceptionally severe heavy duty service, is the following, in which all parts indicated are by weight:

Eample No. 2

Parts by weight A suitable formula which may be followed', in 55 the practice of the present invention, in making friction elements for use as brake linings upon passenger automobiles, light trucks, and the like, is the following, in which all parts indicated are by weight:

Example No. 3 60 Parts by weight Crude (natural) rubber cement 13.25 Oil modified phenol-formaldehyde flexible resin White lead Pyrobituminiius,l material (soft coal, finely divided) Sulphur p vulcanized butadiene-acrylonitrile copolymer synthetic rubber-like elastoprenel (finely divided, dust-like particles, vulcanized with ten per cent sulphur, by

weight) 3.0 Asbestos fiber 65.0 75

, 10 f i. The compositions illustrated in the foregoing Examples Nos. 1 and 2 may be converted into heavy duty type friction elements by intimately mixing the ingredients thereof and forming the 5 resulting mixture into friction element shapes and then effecting thecure of the @rganic bonding agent, as by lthe application of heat alone, or by the application of` both heat and pressure. Thus, in lthe manufacture of friction elements employingythe composition which is illustrated in the foregoing Example No. 2, a temperature of from about 300 F. to about 325 F., and the application of a pressure of about two thousand pounds .per square inch, for about four hours, are suitable, it being understood that the preferred or optimum temperature, pressure rand application time stated above may be varied somewhat depending in part upon the particular composition and the specic temperature, pressure and application time employed. However, in the manufacture of friction elements employing either the composition which is illustrated in the foregoing Example No. 1, or the composition which is illustrated in the foregoing Example No. 3, the

application of heat alone is sufficient to effect the cure of the bond and a typical example of suitable progressively increasing temperatures and application times which may be employed is as follows: Three hours at 225 F.; three hours at 275 F.; three hours at 300 F.; and three v hours at 315` F.

As pointed out hereinbefore, the hardness and heat resistance and related properties and characteristics of the finely divided or dust-like particles of' the .butadiene-acrylonitrile copolymer` friction-stabilizing material, which are referred to in the foregoing Examples Nos. 1 to 3, inclusive, may be readily varied and controlled by selecting and employing in the making of said finely divided friction-stabilizing particles, for a given sulphur content, a synthetic rubber-like elastoprene 'material of the butadiene-acrylonitrile copolymer type containing a predetermined "or preselected percentage ofacrylonitrlle as a component of the .copolymer material. Thus, the relative hardness and heat resistance of said finely divided or dust-like particles of friction-stabilizing material may be increased by employing in the making of said particles a butadiene-acrylonitrile copolymer containing a. relatively high percentage of acrylonitrile as a component of the copolymer material as is true, for example, in the case of Hycar OR (5-15 or 25), Chemigum" (X and I), andin certain of the mateL rials known as Stanco and in the materials known as Standard" and Per-bunan. On the other hand, if desired, the relative hardness and heat resistance of said finely divided particles of friction-stabilizing material may be decreased by employing in the making thereof a butadiene acrylonitrile copolymer containing' a relatively low percentage of acrylonitrile as a component of the copolymer material as in the case', for example, of "Hy'car Ninene B, and in certain of the materials known as Stanco.

It may be' added, at this point. thatthe percentage of acrylonltrile in the various butadieneacrylonitriie copolymer materials or elastoprenes referred to above, varies from a lower` range of the order of approximately fifteen per cent, by weight, in the case of Hycar Ninene B and in certain of the materials known as Stanca to an upper range of the order of approximately fifty per cent, or slightly less, by weight, in the case of Hycar OR (5) and in certain of the materials ever, that the aforesaid ranges are merely illustrative and not critical and that butadiene-acrylonitrile copolymers containing a percentage of acylonitrile below or above these ranges may be employed within the scope and ,contemplation oi the present invention.

It will thus be seen that the hardness and heat resistance and related properties and characteristics of said finely divided or dust-like particles of friction-stabilizing material may bev easily and readily controlled, in the practice of the present invention, and suited to the particular needs, re- `quirements and uses of friction elements in which said finely divided or dust-like friction-stabilizing particles are to be employed.

It will be noted, in this connection, however, that strength is not an essential propertyy or characteristic of the aforesaid finely divided or dustlike friction stabilizing particles and hence in making such particles a butadiene-acrylonitrile copolymer may be employed which contains a y relatively'low percentage of acrylonitrile.V However, in those instances wherein the butadieneacrylonitrile copolymer material is to be employed as a bonding agent in friction elements, strength is a highly desirable and important property and characteristic and hence for such purposes and uses a butadiene-acrylonitrile copolymer material is preferred which contains a relatively high percentage of acrylonitrile in the copolymer. In other words, in such instances, the hardness, heat resistance, and strength of the bonding agent may be easily and readily controlled and increased by selecting therefor a butadiene-acrylonitrile coployed inthe form of dust-like materials or finely divided dispersed discrete particles as frictioncontrolling agents in friction elements, namely, finely divided particles composed assentially of cashew nut shell liquid polymer, finely divided particles composed essentially of a heat polymerized vegetable drying oil such, for example, as

linseed, or finely divided particles composed of f soft scrap rubber dust, as well as the results of corresponding heat tests made upon materials which have been found useful as friction-controlling agents in friction elements in the practice of thepresent invention, namely, finely divided or dust-like particles of vulcanizable synthetic rubber-like elastoprenes of the butadieneacrylonitrile copolymer type.

The abscissae in Fig. l represent the loss Ain terms of per cent by weight of the specimens tested and the nature of the materials tested and the times and temperatures involved in the tests 'are shown at the left in Fig. 1.

In making the tests which are illustrated in the graphs shown in Figs. 1 and 2, synthetic vulpolymer containing a relatively high percentage of acrylonitrile since, as pointed out hereinbefore, the hardness, heat resistance, and strength of such a bonding agent increase in direct relationship to the percentage of the acrylonitrile in' the copolymer material. Moreover, this is true regardless of the particular brand of synthetic rubber-like clastoplastic of the butadiene-acrylonitrile copolymer type which may be employed and regardless of the particular catalytic and emulsiiying and other agents which may be employed in the process of making the particular or selected butadiene-acrylonitrile copolymer material.

It may be desirable and advantageous, in certain instances, and for particular uses .or purposes, to employ in making said finely divided or dust-like friction-stabilizing particles a mixture or mixtures of two or more butadiene-acrylonitrile copolymer materials of the character hereinbefore referred to so as to combine selected desirable characteristics thereof.

It will be noted, in this connection, that a typical and suitable manner of effecting substantially uniform distribution of the finely divided particles of the material found useful as a friction-controlling and friction-stabilizing agent throughout the resulting friction elements is to intimately mix said particles with the organic bonding agent prior to the time the organic bonding agent' is intimately mixed with the friction material. However, the invention is not limited to this procedure and said finely divided particles may, if desired, be intimately mixed with the friction material and bonding agent after the friction material and bonding agent have been mixed together.

The graphs illustrated in Figs. 1 and 2 of the drawings show, among other things, the results of heat tests made upon materials heretofore emcanized rubbery elastoprenes of the butadieneacrylonitrile copolymer type (Hycar Or" and Perbunan) were compounded in one instance, with ve per cent by weight of sulphur and in another instance with ten per cent by weight of sulphur, and the materials were sheeted, vulcanized by heat, chilled, cured and pulverized to a particle size of approximately 40 mesh. A one gram specimen of `each of the iinely divided or dust-like materials thus formed was then heated and tested under carefully controlled conditions including the controlled conditions'of time and temperature which are shown in the graphs; comparable specimens composed essentially of cashew nut shell liquid polymer, heat polymerized drying oil (glycerol ester of fatty acid polymer known as Neofat), and finely divided particles composed of soft scrap rubber dust, all having the same particle size, were heated and tested under identical conditions, with the results indicated in the graphs which are illustrated in Figs. l and 2.

It may be added, at this point, that the heat polymerized drying oil employed in making certain of the specimens was the most stable and most completely heat polymerized drying oil cur-v rently available commercially, and is known by the trade name Neofat, and is a. product resulting from substantially complete heat poly merizati'onof a glycerol ester of a fatty acid of animal origin so that the heat tests made show, among 4,other things, the results of comparative heat resistance andA other properties of finely divided particles of a relatively highly stable and completely polymerized drying oil and the correspondingproperties of the lmaterials which have been found useful as friction-controlling agents in friction elements in the practice of the present invention.

While, as pointed out above, the new finely divided or dust-like friction-controlling materials may be compounded with either ve per cent or ten per cent, by weight, of sulphur, about ten per cent, by weight, of sulphur is preferred because approximately this percentage of sulphur assures suilicient hardness in the resulting vulcanized material to enable it to be granulated or formed into iinely divided or dust-like particles while also assuring that` such particles will possess sufilcient resiliency to render them useful as friction-controlling agents or ingredients in friction elementsin the practice of the present invention. I l

The graphs in Figs. 1 and 2 show, among other things, the percentage of acetone-soluble or une polymerized monomer fraction or material present in the specimens prior to their being subjected to the heat tests; the loss in weight in terms of per cent in the specimens tested as measured by the percentage of acetone-soluble monomer or depolymerized material, and other acetone-soluble material resulting from the heat decomposition of the heat' polymerized oils employed in preparing certain of the specimens, due to the heat tests madethereon; the loss in weight in terms of per cent in the specimens tested as measured by the percentage of benzol-soluble material formed in certain of the specimens and resulting from heat decomposition thereof during the heat tests; and the loss in 'weight in ,terms of per cent in the specimens tested as measured by the-percentage of volatile materials given off by the Hspecimens during and as a result i of the heat tests.

It will be noted, in this connection, that the percentage of acetone-soluble material which was' present in the specimens tested after they had been subjected to the heat tests, is a measure of the percentage of monomer fraction or heat depolymerized material, and other products of heat decomposition, in general, present in such specimens afterA they had been subjected to the heat tests. This test is also a measure of the percentage of the products of heat polymerization and heat decomposition, in general, formed in friction elements containing such materials when said friction elements are subjected to the temperatures to which such friction elements are subjected in use.

Similarly, the percentage of benzol-soluble ma,- terial present in certain of the specimens, after they had been subjected to the heat tests, is a measure of the extent to which such specimens tested had undergone heat decomposition during and as a result of the heat tests, and this test is employed as a measure of the extent to which the friction-controlling materials referred to in certain of the graphs have undergone heat Ader terioration or decomposition.

The percentage of .volatile material present in the specimens, after they had been subjected to the heat tests, is also a measure of the comparative stability of such materials when used as friction-controlling' agents or ingredients in friction elements, and further indicates the extent or degree of heat decomposition of the materials tested.

As indicated at I Il; in Fig, 1, a specimen of finely divided granules or particles composed essentially of butadiene-acrylonitrile copolymer synthetic vulcanized rubbery elastoprene, vulcanized with five per cent, by weight, of sulphur when tested at atmosphere temperature contained about 4.67 per cent acetone-soluble unpolymerized or monomer material. However, as may likewise be seen by reference to Fig, 1, and as therein indicated at II', a specimen of finely divided particles or granules of butadiene-acrylonltrile copolymer synthetic vulcanized rubbery elastoprene, vulcanized with five per cent, by weight, of sulphur, after having been vheated for 19.5 hours at a substantially constant temperature of 260 C., contained only about 0.28 per cent,' by weight, of acetone-soluble or monomer material, thus indicating the marked stability of this material and its resistance to heat decomposition or heat depolymerization,

As indicated at I2 in Fig. 1, a specimen of nely divided particles of butadiene-acrylonitrile copolymer synthetic vulcanized rubbery elastoprene, vulcanized with five per cent, by weight, of sulphur, showed a loss of only about 5.26 per cent, by weight, as measured in terms of volatile material, after having been subjected to a substantially constant temperature of 260 C. for a period of 19.5 hours. Moreover, as indicated at I3 in Fig. 1, a specimen of this material showed a loss of only 0.21 per cent by weight, as measured in terms of benzol-soluble material, after having been subjected to a substantially constant temperature of 260 C. for 19.5 hours, thus indicating the'high'degree oi. resistance to heat decomposition possessed by this material.

As indicated at I4 in Fig. 1 a specimen of finely divided\particles composed essentially of butadiene-acrylonltrile copolymer vulcanized with ve per cent, by weight, of sulphur contained about eight per cent by Weight, of acetone-soluble or monomer material, and a specimen of the same material showed a loss of about 6.5=per cent, by weight, as measured in terms of loss of volatile material, after having been subjected to a substantially constant temperature of 315 C. for a period o f one hour, as indicated at I5 in Fig. 1.

As indicated at I6 in Fig. 1, a specimen of finely divided lparticles composed essentiallyl of butadiene-acrylonitrile copolymer type synthetic vulcanized rubbery elastoprene, vulcanized with ten per cent, by` weight, of sulphur, when tested at atmospheric temperature, contained about 4.58 per cent, by weight, of acetone-soluble or depolymerized material.

A specimen of finely divided particles composed essentially of butadiene-acrylonitrile copolymer compounded with ten per cent, by weight, of sulphur, showed a loss of about 5.60 per cent, by weight, as measured in terms of volatile material, after having been subjected to a substantially 19.5l hours, as indicated at 38 in Fig. 1.

As indicated at I1 in Fig. 1, a similar specimen of this material after having been subjected to a substantially constant temperature of 260 C.

for a period'of l19.5 hours showed a loss by weight,y as measured in terms of acetone-soluble materiah of only about 0.27 per cent, therebyl exhibiting the marked resistance to heat depolymerization possessed by this material. f i

A specimen of-'finely divided particles composed essentially of butadiene-acrylonitrile copolymer type syntheticv vulcanized rubbery elastoprene, compounded or vulcanized with ten per cent,fby weight, of sulphur, showed a loss in weight, as measured in terms of benzol-soluble material, of only 0.22 percent, after having been subjected to a substantially constant temperature of 260 C. for" a period of 19.5 hours, as indicated at I8 in Fig. 1.`

As indicated at I9 -in Fig. 1, a similar specimen of this material when subjected to a substantially constant temperature of 315 C, for a period of one hour, showed a loss of only about 7.6 per cent, by weight, as measured in terms of loss' of volatilematerial, and, as indicated at 20 in Fig. 1, va similar specimen of the'same material showed a loss of only about 7.4 per-cent, by weight, as measured in terms of acetone-soluble material, when subjected toa substantially constant temperature of 315 C. for a period of one hour, thereby further demonstrating the marked resistance possessed by this material to heat detericomposed essentially of butadieneacrylonitrile --the practice of the present invention.

As may be seen by reference to Fig. 1, and as therein indicated at 2l, a specimen of finely divided particles or granules composed essentially. of cashew nut shell liquid polymer, when tested at atmospheric temperature, showed about 14.20 per cent, by weight, of acetone-soluble material, thereby exhibiting the presence in this material of a substantially greater amount or percentage of unpolymerized material or monomer fraction than is present in the finely divided particles Fig. 1).

As may also be seen by reference to Fig. 1, and as therein indicated at 2, a specimen of finely divided particles ccmposedessentlally of cashew nut shell liquid polymer, when heated for a period of 19.5 hours at a substantially constant temperature of 260 C., showed a loss in weight of 16.87 per cent, as measured in terms of loss of volatile material.

A specimen of finely divided particles composed essentially of cashew nut shell liquid polymer showed a loss of 2.72 percent, by weight, as measured vin terms of acetone-soluble material, after having been exposed to al substantially constant temperature of 260 C. for a period of 19.5 hours, as indicated at 23 in Fig. 1. as compared to losses of only 0.28 and 0.27 percent. by weight, in the case of specimens'of finely divided particles composed essentially of butadiene-acrylonitrile copolymer synthetic elastoprene compounded with ve percent and ten percent, by weight, respectively, of sulphur (see graphs II and I1, respectively, in Fig. 1), when heat tested under identical conditions. This demonstrates the superior resistance to heat depolymerization and heat decomposition, in general, which is pos` sessed bythe materials found useful as frictioncontrolling ingredients in friction elements in the practice of the present invention compared to friction-controlling material composed essentially of finely divided particles of` cashew nut shell liquid polymer. 1

As indicated at 24 in Fig. 1, a Specimen of finely divided particles composed essentially f cashew nutshell liquid polymer showed a loss of 0.22 percent, by weight, as measured in terms of benzolextractable material, after lhaving been exposed to a substantially constant temperature of 260 C. for a period of 19.5 hours.

Graph 25 in Fig. l shows-that a specimen of I iinely divided particles composed essentially of cashew nut shell liquid polymer, when heated for a period of cnehour at a substantially constant temperature of 315 C., showed a loss .of about twelve percent, by weight, as measured in terms of loss of volatile material and graph 26 in Fig. 1 shows that a specimen of the same material when subjected tothe same conditions or heat test showed a loss of about 3.40 percent, by weight, as measured' in terms 'of acetone-soluble material. Graph 21 in Fig. 1 shows that a specimen of finely divided particles of a heat-polymerized dry- -ing oil (glycerol ester of fatty acid polymer known by and commercially available under the trade name Neofat) when tested at atmospheric temperature contained 47.28 percent, by weight. of

acetone-soluble material, thus indicating the relatively very high percentage of unpolymerized or acetone-extractable monomer fraction present in this `material as compared to the relatively very low percentage of unpolymerized or acetonesoluble monomer fraction which is present, at atmospherlc temperatures, in the materials which have been found useful as friction-controlling or friction-stabilizing agents in friction elements. in the practice of the present invention. This coin-4 parative relationship may be seen by comparing graphs I0 and I6 with graph 2 1 in Fig. 1. l

Graph 28 in Fig; i'sliows that a specimen ot finely divided particles composed essentially of a heat polymerized' dryingcil (the glycerol ester of `fatty acid polymer which is referred to in the .preceding paragraph) showed aloss in weight of 28.72 percent, as measured in terms of loss of 4volatile material, after having been subjected to a substantially constant temperature of 260 C. for a period of 19.5 hours, thus indicating the relatively poor or low resistance of this material to heat decomposition, as compared to the relatively high heat resistance possessed by the materials which have been found useful as frictioncontrolling or friction-stabilizing ingredients in friction elements, in the practice of the present invention. This comparative relationship may be seen by comparing graphs I2 and 3B with graph 28 in Fig. 1.

Graph 29 in Fig. 1 shows that a 'specimen of finely divided particles composed essentially of the heat polymerized drying oil which is referred to above in connection with graphs 21 and 28. showed a loss in weight of 1.76 percent, as measured in terms of -acetone-extractable material, after having been subjected to a substantially constant temperature of 260 C. for a period oi' 19.5 hours. It will be noted, in this connection, howeveathat while this material exhibited a relatively small percentage of acetone-soluble depolymerized or monomer fraction. and other acetone-soluble products resulting from the heat decomposition of the oil employed in preparing this specimen, after having been subjected to the heat test described, its relatively low percentage of acetone-extractable material was due, not to any high degree of resistance of this material to heatdepolymerization and heat decomposition, in general, but to the fact that this material underwent a high degree of carbonization during this heat test. Moreover, the relatively poor resistance of this material to heat decomposition is shown by graph 28 in Fig. 1 which shows the relatively high percentage of volatile matter lost by this material after having been subjected to the heat test Just described. l

Graph 30- in Fig. 1 shows that a specimen of nely diviied particles composed essentially oi.'

the heat polymerized drying oil, which has been referred to above in connection with graphs 2l andi29, showedv a loss of only about 0.34 percent, by weight, as measured in terms of benzol-extractable material, after having been exposed to a substantially constant temperature of 260 C. for a period of 19.5 hours. However. the rela'- tivelyy low percentage of benzol-extractable ma.- terial developed by this specimen in the heat test just described was not due to good or high resistance of this material to heat decomposition but was dueto the fact that the specimen underwent a high degree of carbonization during the heat test. Moreover. the relatively poor re sistance of this material to heat decomposition is shown by the relatively high degree of percentage 17 of loss by weight, as measured in .terms of loss of volatile material, shown by graph 28 in Fig. 1, and as described hereinbefore.

Graph 3| in Fig. l shows'that a specimen of nely divided particles composed essentially of the heat polymerized drying oil, which has been referred to hereinbefore in combination with graphs 2l, 28, 29 and 30, showed a loss by weight of about 23.5 per cent, as measured in terms of loss of volatile material, after having been subjected to a substantially constant temperature of 315 C. for a period of one hour, thereby indicating the relatively poor or low resistance of this material to heat decomposition at temperatures encountered by friction elements in use, and as compared to the relatively high heat resistance possessed by the materials found useful as friction-controlling or friction-stabilizing ingredients in friction elements, in the practice of the present invention. This comparative relationship may be seen by comparing graphs I5 and I9 with graph 3| in Fig. l. l

Graph 32 in Fig. 1 shows that a specimen of finely divided particles composed essentially of the heat polymerized drying oil, which has been referred to above in connection with graphs 21, 28, 29, 3U and 3|, showed a loss by weight of approximately 6.5 per cent, as measured in terms of acetone-extractable material, after having been subjectedto a substantially constant temperature of 315 C. for a period of one hour. It will again be noted, however, that the relatively low percentage of acetone-extractable material exhibited by this specimen, after the heat test just described, was not due to its resistance to heat-depolymerization or to heat decomposition, in general, but was due to a marked degree, of carbonization of the specimen at the temperature involved in the test. Moreover, the relatively poor resistance of this material to heat decomposition, as shown by the relatively high percentage of loss by weight, as measured in terms of loss of volatile matter, exhibited by this vmaterial, compared to the materials employed as friction-controlling or friction-stabilizing ingredients in friction elements, in the practice of the present invention, has been pointed out hereinbefore in connection with graph 3| and may be seen by comparing graphs I5 and I9 with graph 3| in Fig. 1.

Graph 33 in Fig. 1 shows that a specimen composed essentially of finely divided particles of soft scrap rubber, vulcanized with a relatively low percentage of sulphur (from 2 to 6 per cent), contained approximately 4.91 per cent of unpolymerized or acetone-soluble monomer fraction when tested at atmospheric temperatures.

Graph 35 in Fig. 1 shows that a specimen of' finely divided particles composed essentially of soft scrap rubber dust, vulcanized with a relatively low percentage of sulphur (from 2 to 6 per cent), showed a loss by weight of 5.76 per cent, as measured in terms of loss of volatile material, when subjected to a substantially constant temperature of 260 C. for a period of 19.5 hours.

or low resistance possessed by this material to heat-depolymerization and heat decomposition, in general, at temperatures encountered by friction elements in use, compared to the relatively high resistance to heat-depolymerization and heat decomposition, in general, which is possessed by the materials which have been found useful as friction-controlling or friction-stabilizing ingredients in friction elements, in the practice of the present invention. This comparative relationship may be seen by comparing graphs and I1 with graph 36 in Fig. 1.

The specimens of finely divided particles composed essentially of soft scrap rubber dust, vulcanized with a relatively low percentage of sulphur (2 to 6 per cent), and the results of heat tests upon which are illustrated in graphs 35 and 36 in Fig. 1, all liquefied during these heat tests and when exposed to a substantially constant temperature o f 260 C. for a period of 19.5 hours.

Hence, it was impossible to subject specimens of this material to heat tests at the higher temperature of 315 C., as was done in the case of the specimenscomposed of the other materials which are referred to in Fig. 1. This further indicates the poor or low heat resistance .possessedby finely divided particles of soft scrap rubber,.

vulcanized with a relatively low percentage of sulphur, such as from 2 to 6 per cent, and the consequent unsuitability of this material for use as a friction-controlling or friction-stabilizing ingredient in friction elements, as evidenced by the fact that this material liquees at temperatures which are frequently encountered in the use of such friction elements.

It is to be noted; in connection with the materials which have been found useful as frictioncontrolling and friction-stabilizing ingredients in friction elements.. in' the practice of the present invention, that the nely divided particles composed essentially of butadiene-acrylonitrile copolymer compounded with ten per cent, by weight,

of sulphur, are somewhat harder than the -same materials compounded with ve per cent, by weight, of sulphur. Moreover, the variations or gradations in hardness of these materials correspond, in a general way, or are analogous to, the various gradations of hardness in finely divided particles composed essentially of cashew nut shell liquid polymer, and the hardness of which latter particles depends largely upon the degree of polymerization of the cashew nut shell liquid polymer of which such materials are composed. A significant difference, however, between the materials which have been found useful as frictioncontrolling or friction-stabilizing agents in friction elements, in the practice of the present invention and finely divided particles composed essentially of cashew nut shell liquid polymer resides in the'fact that the softer forms of finely divided particles of cashew nut shell liquid polymer are substantially less resistant to heat-depolymerization and heat decomposition, in general, and give off substantially more volatile material than harder forms of finely divided particles composed essentially of cashew nut shell liquid polymer. It is to be noted. however, that a comparable or like situation does not exist in regard to the materials employed as friction-controlling or friction-stabilizing agents in friction elements in the practice of the present invention since the nely divided particles composed Vessentially of butadiene-acrylonitrile copolymer terial exhibited by this specimen shows the poor 75 compounded with ve per cent, by weight,A of sul- -19 phur possess substantially the saine degree or order of heat resistance that is possessed by finely divided particles of the samematerial compounded with ten' per cent, by weight, of sulphur. However, since, as pointed out elsewhere herein, the particles of this materialcompounded with ten per cent, by weight, of sulphur are somewhat harder and hence easier to break up into the de-4 sired particle size, the material compounded with ten per cent, by weight, of sulphur is preferred.

It is desirable that finely divided particles of friction-controlling or friction-stabilizing materials, in friction elements, be at least as heat-resistant as the organic bonding agents which are employed in suchfrictionelements. Itispreferred, however, 'that such finely divided particles of friction-controlling and friction-stabilizing materials preferably have substantially greater resistance toheat depolymerization and heat decomposition, in general, than is possessed by the organic bonding agents which are employed in friction elements and in which such finely divided particles of friction-controlling or frictionstabilizing materials may be dispersed.v

It is significant to note, however, and we have so ascertained, that finely divided particles composed essentially of soft scrap rubber, vulcanized with a low percentage of sulphur, such as from 2 to 6 per cent, not only possess relatively poor or low resistance to heat depolymerization and heat decomposition, in general, at temperatures to which friction elements are commonly subjected in use, but such nely divided .particles of soft rubber scrap are, in fact, substantially less resistant to heat depolymerization and heat decomposition, in general, at such .temperatures than are the organic bonding agents which are commonly employed in friction elements and such, for example, as an oil modied phenol resin, or natural hard rubber vulcanized with a high percentage of sulphur and protected by means of a phenol resin. Moreover, as shown in the graphs illustrated in Figs. 1 and 2, the heat resistance of such finely divided particles of soft scrap rubber, vulcanized with a low percentage of sulphur, is vnot substantially superiorto the heat resistance of nely divided particles of polymerized drying oils which, in turn, are substantially inferior in heat resistance to finely divided par- `ticles of the materials which have been found useful as friction-controlling and friction-stabilizing materials in friction elements in the practice of the present invention.

Fig. 2 is a graph illustrating the results of tests made upon specimens of certain of the frictioncontrolling materials which were employed in making the heat tests, the results of which are shown in Fig. 1, namely, a specimen of finely divided particles composed essentially of heat polymerized drying oil (glycerol ester of fatty acid polymer) (graph l in Fig. 2); a specimen of nely divided particles composed essentially of cashew nut shell liquid polymer (graph 2 in Fig. 2); and a specimen of finely divided particles of the material which has been found useful as a frictioncontrolling ingredient in friction element in the practice of the present invention, namely, butadiene-acrylonitrile copolymer type synthetic vuloanized rubbery elastoprenes, compounded with ten per cent by weight of sulphur.

, The abscissae in Fig. 2 represent the number of hours at which the specimens were subjected to heat tests at a substantially constant tem- 20 measured in terms of benzol-extractable material.

As shown in Fig. 2, the specimen of finely divided particles composedessentially of heat polymerized drying oil (glycerol ester of fatty acid polymer) showed a substantial percentage of loss by weight, as measuredv in terms of benzol-extractable material, namely, approximately 18 per cent, when heated for only adrelatively short period of between 1 and 2 hours at a substantially constant temperature of 500 F. As shown by graph I in' Fig. 2 this specimen showed a further increase in loss of weight, up to about 33 per cent,

as measured in terms of benzol-extractable material, during the remainder of the heat test, thereby indicating its poor resistance to heat decomposition at temperatures to which friction elements are frequently subjected in use.

Graph 2 in Fig. 2 shows that a specimen of nely divided particles composed essentially of cashew nut shell liquid polymer also exhibited substantially greater loss by weight, as measured in terms of loss of benzol-extractable material, than was exhibited by the specimen of nely divided particles of material found useful as a friction-controlling and stabilizing agent in friction elements in the practice of the present invention, namely, finely divided particles composed essentially of butadiene-acrylonitrile copolymer type synthetic vulcanized rubbery elastoprenes, componded with about ten per cent, by weight, of rubber, as may be seen by comparing graphs I and 2 with graph 3 in Fig. 2. l

It will thus be seen from the foregoing description, considered in conjunction with the graphs which are shown in Figs. 1 and 2, that finely divided particles of material found useful as a friction-controlling and friction-stabilizing agent in friction elements. in the practice of the present invention, namely, finely dividedv particles composed essentially of butadiene-acrylonitrile copolymer type synthetic vulcanized rubbery elastofriction elements, and which have been referred to hereinbefore.

It will be seen, therefore, from the foregoing description, considered in conjunction with the accompanying drawings, that the present invention affords a new and improved friction element, and a new and substantially superior friction-controlling and friction-stabilizing agent for friction elements. It will also thus be seen that friction elements containing the material found useful as a friction-controlling agent in the practice of the present invention have the desirable properties and characteristics, which have hereinbefore been pointed out, as well as others which are inherent in the invention, and including greater friction stability, greater resistance to heat depoiymerization, and to heat decomposition, in general, and to softening, and greater resiliency, at temperatures to which friction elements are subjected in use, than is possessed by the materials heretofore employed as friction-controlling agents in friction elements.

It will thus be seen that friction elements made according to the practice of the present invention possess the desirable characteristics hereinbefore mentioned, as well as others which are inherent friction elements'or products having the advantages and desirable characteristics hereinbefore set forth and others inherent therein.

While we have illustrated and described selected embodiments of our invention, and of the new friction elements made in the practice thereof, it is to be understood that these are capable of variation and modification and we do not, therefore, wish to be limited to the precise details of the friction elements, composition and method which are set forth but desire to avail ourselves of such changes and modifications as come within the purview of the following claims.

We claim:

1. A friction element for use upon vehicular brakes, and upon clutches, comprised of a mass of friction material, inert ller, and a frictionmodifying agent, bonded with the heat-reaction product of a mixture of a sulphurizable heatpolymerized linseed oil, together with a heat-resistant phenol-aldehyde resin, and sulphur, the said sulphurizable heat-polymerized linseed oil and the said heat-resistant phenol-aldehyde resin and the said sulphur being employed as components of the said bond in the ratios relative to each other of 8.4 parts of heat-polymerized linseed oil to 8.4 parts of heat-resistant phenolaldehyde resin and 2.5 parts of sulphur, al1 of said parts being by Weight; the said bond having dispersed therethrough finely divided, dust-like, resilient, friction-stabilizing particles of a copolymer of a member of the group consisting of butadiene 1,3 and 2 methyl butadiene 1,3 and a member of the group consisting of acrylic acid nitrile and methacrylic acid nitrile, the said finely divided dust-like resilient, friction-stabilizing particles being employed as a component of the said bond in a partially vulcanized condition as compounded with not less than five per cent nor more than ten per cent of the unvulcanized copolymer, by weight, of sulphur, the said finely divided, dust-like, resilient, friction-stabilizing particles being employed as a component of the said bond in the amount of 17.2 per cent of the said bond, by weight, and the said friction element being characterized by friction stability and high resistance of the said nely divided, dustlike, resilient, friction-stabilizing particles to heat-depolymerization and resulting heat-decomposition when the said friction element is subjected to elevated temperatures in use.

2. A friction element as defined in claim 1 in Which the said heat-resistant phenol-aldehyde resin is a heat-resistant phenol-formaldehyde,

resin.

3. A friction element as defined-in claim 1 in which the said heat-resistant phenol-aldehyde resin is a heat-resistant oil-modified phenol-formaldehyde resin. A

4. A friction element as defined in claim 1 in which the hydrocarbon component of the said copolymer of which the said nely divided, dustlike, resilient, friction-stabilizing particles are formed is 1,3 butadiene.

5. A friction element as dened in claim 1 in which the hydrocarbon component of the said copolymer of which the said finely divided, dustlike, resilient, friction-stabilizing particles are formed is 2-methyl 1,3 butadiene.

6. A friction element as defined in claim 1 in which the acrylonitrile component of the unv-ulcanized-butadiene'L3 acrylonitrile copolymer of which the said finely divided, dust-like, resilient, friction-stabilizing particles are formed is acrylic acid nitrile.

7. A friction element as dened in claim 1 in which the acrylonitrile 'component of the unvulcanized butadiene 1,'3 lacrylonitrile copolymer of which the said finely divided, dust-like, resilient, friction-stabilizing particles are formed is methacrylic acid nitrile.

8. A friction element 'asdened in claim 1 in which the acrylonitrile component of the said butadiene 1,3 acrylonitrile of which the said nely divided, dust-like, resilient, friction-stabilizing particles are formedconst'itutes not less than fifteen per cent nor more than fifty per cent of the said unvulcanized butadiene 1,3 acrylonitrile copolymer, by weight. i RAY E. SPOKES.

EMIL C. KJLIIiElIt.4 

